lock JAGUAR XJ6 1994 2.G Repair Manual

Brakes (e#
12.1.7. Parking Brake
J70 293
W
1. Parking brake lever 2. Front cable 3. Relay lever 4. Driveshaft securing bracket 5. Intermediate cable 6. Cable equalizer
7. In-line cable connector 8. Rear cable RH 9. Rear cable LH
10. Parking brake switch and harness 11. Parking brake warning lamp
Fig.
1 Parking Brake Layout
All vehicles are fitted with identical parking brake systems.
When the parking brake lever
is operated, the cable system applies equal force to both RH and LH brakeshoe expander
assemblies. The brake shoes expand and press against the hub assembly, locking the rear wheels.
The handbrake lever, ratchet assembly and warning
light switch (item 1) are mounted on the transmission tunnel by means of threeflanged screws a blanking plate and gasket. The front cable (item 2) is connected to the relay lever (item 3) which is mounted on the driveshaft securing bracket (item 4). The relay lever operates the intermediate cable (item 5) which incorporates an adjusting screw to allow cable tension to be adjusted. The intermediate cable operates the
equalizer which ensures that equal force is applied to RH and LH parking brakesvia rearcable RH (item 8) and rear cable
LH (item 9). The rear cables are adjustable to allow cable tension to be adjusted.
The park brake switch (item 10) latches when the lever
is operated and lights the parking brake warning light (item 11 mounted in the instrument panel.
X300 VSM Issue 1 August 1994

12.1.9
The TMC primary circuit (item 1) applies brake pressure to the front brakes. Individual control of the front wheels is
provided by solenoid valves, Valves (items
15 and 18) control the front left brake circuit (item 21). Valves (items 16and 19) control the front right brake circuit (item 22). The TMC secondary circuit (item 2) applies brake pressure to the rear
brake circuit (item 20) via valves (items 14 and 17), on a 'select low' principle.
Hydraulic Operation - A BS CM
8
I I + I
I t 1
'0281
1. TMC 1 (primary circuit) 9. Low pressure accumulator 17. Outlet valve NC 2. TMC 2 (secondary circuit 10. Electric pump motor 18. Outlet valve NC
3. Tandem master cylinder 11. Two circuit hydraulic pump 19. Outlet valve NC 4. Vacuum booster 12. Damping chamber 20. Rear brake circuit 5. Central valve 13. Valve block 21. Front brake circuit (left)
6. Fluid reservoir 14. Inlet valve NO 22. Front brake circuit (right) 7. Fluid level indicator 15. Inlet valve NO 8. Pump motor unit 16. Inlet valve NO
Fig.
1
Should the ABS be initiated by a locking tendency of any wheel during braking, the pump unit (item 8) is started and
the appropriate NO inlet valve (item 14, 15 or 16) closes in response to signals from the control module. This action
prevents further increase of brake pressure by blocking the supply of brake fluid from the TMC (item 3). If excessive
deceleration continues, the appropriate NC outlet valves (item 17,18 or 19) opens, releasing brake pressure to the low
pressure accumulators (item 9) until the wheel accelerates again.
Issue 1 August 1994 12 X300 VSM

12.1.1 0 Hydrauric Operation - ABS 1 TC CM
ABS/TC CM hydraulic modules incorporate inlet valves (items 16 and 17) and outlet valves (items 20 and 21) for each
driven wheel. This enables individual pressure modulation to the rear brakes under wheel spin conditions, i.e. traction
control.
Increased wheel spin of
a driven wheel under acceleration causes the NO isolation valve (item 14) to be closed and the
pump (item 10) to be switched on. This in response to signals from the control module.
Closing of the isolation valve blocks delivery of the pump to the secondary circuit (item
2) of the TMC. The pump now
draws fluid from the reservoir via the open hydraulically operated inlet valve (item 13). Increased pressure is now avail-
able at the inlet valves (items 16 and 17) for actuating the rear brakes, thus decreasing the tendency of wheel spin.
The hydraulic inlet valve (item
13) switches when traction control is initiated to change the suction connection
of the pump from the accumulators (item 9) to the fluid reservoir (item 6) via the TMC.
1. TMC 1 (primary circuit)
8
I 1-
I
10. Electric DumD motor 19. Inlet valve NO
170 280
2. TMC 2 (secondary circuit) 11. Two-cirh hydraulic pump 20. Outlet valve NC
3. Tandem master cylinder 12. Damping chamber 21. Outlet valve NC
4. Vacuum booster 13. Hydraulic inlet valve 22. Outlet valve NC
5. Central valve 14. Isolation valve NO 23. Outlet valve NC
6. Fluid reservoir 15. Relief valve 7. Fluid level indicator 16. Inlet valve NO 8. Motor pump unit 17. Inlet valve NO 9. Low pressure accumulator 18. Inlet valve NO
Fig.
1 24.
Rear
brake circuit (left) 25. Rear brake circuit (right) 26. Front brake circuit (left) 27. Front brake circuit (right) ~
Issue 1 August 1994 14 X300 VSM

12.2 FAULT DIAGNOSIS AND TESTING
rrouble
-ong brake pedal
dibration during braking
'oor braking performance
3rakes pull to one side
3rakes do not release
ixcessive pedal travel
Cause
Brake caliper piston or caliper guide
pins sticking
Worn
I damaged brake pads
Worn
1 damaged brake pads
Loose caliper mounting bolts
Insufficient grease on sliding parts
Foreign material
or scratches on
brake rotor contact surface
Damaged brake rotor contact surface
Leak
in hydraulic system
Air
in system
Worn
I damaged brake pads
Foreign material on brake pads
Brake caliper piston malfunction
Tandem master cylinder malfunction
Vacuum booster fault
Disconnected
or damaged vacuum
hose
Low brake
fluid level
Worn
I damaged brake pads
Foreign material on brake pad
Failing valves
in ABS valve block
Abnormal wear or distortion on front
brake rotor
Incorrect wheel alignment
Incorrect tire pressure
No brake pedal free play
Vacuum booster
binding
Tandem master cylinder return port faulty
Faulty valve
in ABS valve block
Leak
in hydraulic system
Air
in system
Remedy
Service or renew caliper or caliper
guide pins
Renew brake pads
Renew brake pads
Tighten caliper mounting bolts
Apply grease where necessary
Clean brake rotor contact surface
Renew brake
rotor
Repair leak. Check all pipework con-
nections. Refill and bleed the system
Check the system
for leaks and bleed
brakes
Renew brake pads
Examine brake pads and clean
or
renew as necessary
Renew faulty brake caliper piston
Service
or renew tandem master cyl- inder
Renew vacuum booster
Renew vacuum hose
Check for leaks, refill and bleed the
system
Renew brake pads
Examine brake pads and clean
or renew as necessary
Renew valve block
Examine front brake
rotor and service
or renew as necessary
Carry out wheel alignment. Refer to
Section
11, iv Service Data
Inflate tire
to correct pressure
Adjust brake pedal free play
Renew vacuum booster
Clean return
port on tandem master cy I i nder
Renew valve block
Repair leak. Check all pipework con
- nections. Refill and bleed the system
Check the system
for leaks and bleed
brakes
0
0
0
Issue 1 August 1994 16 X300 VSM

Brakes
a 12.5 GENERAL FI77lNG lNSTRUCTlONS
12.5.1 Brake Fluid
WARNING: BRAKE FLUID IS CORROSIVE. EXTREME CARE MUST BE TAKEN WHEN HANDLING. AVOID SKIN OR EYE
CONTACT. AVOID INGESTION. IF SKIN OR EYES ARE ACCIDENTALLY SPLASHED WITH BRAKE FLUID,
RINSE THE AFFECTED AREA IMMEDIATELY WITH PLENTY OF WATER AND SEEK MEDICAL ATTENTION.
IF BRAKE FLUID
IS INGESTED, SEEK MEDICAL ATTENTION IMMEDIATELY.
CAUTION:
Fluid must not be allowed to contact the vehicle paintwork. Remove any spilt fluid from the paintwork
by rinsing away with running water. Methylated spirit (denatured alcohol) must not be used to clean the
contaminated area.
Cleaning Solvents
CAUTION: Never use methylated spirit (denatured alcohol) for cleaning purposes. Use only a proprietary brake
cleaning fluid.
m: THROUGHOUT THE FOLLOWING MAINTENANCE / SERVICE OPERATIONS, ABSOLUTE CLEANLINESS
MUST BE OBSERVED TO PREVENT GRIT OR OTHER FOREIGN MATTER CONTAMINATING THE BRAKE
TION. TO CLEAN BRAKE SYSTEM COMPONENTS, WASH
IN A PROPRIETARY BRAKE CLEANING FLUID.
REMOVE ALL TRACES OF CLEANING FLUID BEFORE REASSEMBLY. ALL BRAKE SYSTEM RUBBER COh PONENTS MUST BE DIPPED IN CLEAN BRAKE FLUID AND ASSEMBLED USING THE FINGERS ONLY.
SYSTEM.
IFTHE SYSTEM IS TO
BE FLUSHED, USE CLEAN BRAKE FLUID TO MINIMUM DOT 4 SPECIFICA-
12.5.2 Hoses
Fully release the unions (1 Fig. 1) securing each end of the
hose to the fluid pipes. Withdraw the pipe unions (1 Fig. 1) from the hose ends.
Plug the ends of the pipes (2 Fig. 1) to prevent the loss of
fluid and the ingress of dirt.
Remove the mounting bracket locknut (3 Fig. 1) and re- move the hose (4 Fig. 1).
Thoroughly clean the hose and examine for any signs of
wear or damage. Renew the hose if there is any doubt
about its condition. Thoroughly clean the bore of the hose
using compressed air.
. Remove all blanking plugs and fit the new hose to the cali- per / connector. Secure the hose to the mounting bracket.
. Before fully tightening the locknut, ensure that the hose is
neither kinked nor twisted.
. Bleed the brakes.
12.5.3 Pipes
. Fully release the pipe unions (1 Fig. 1).
. Withdraw the pipe (5 Fig. 1) from the vehicle. Plug the
pipes (2 Fig. 1) to prevent the loss of fluid or the ingress of dirt. Thoroughly clean and examine the pipe for signs of damage or deterioration. Renew the pipe if there is any
doubt about its condition.
Thoroughly clean the bore of the pipe using compressed
air.
. Remove all blanking plugs and fit the new pipe to the ve- hicle. Secure the pipe to the body.
. Bleed the brakes.
17
Fig. 1
X300 VSM 21 Issue 1 August 1994

Body Components & Trim .
SECTION CON TENTS
Sub-Section Tit /e SRO Page
I to V ............ Preliminary Pages ................................................................. i to v
13.1
............. General Description ................................................................. 1
13.2 ............. Doorand Fuel FillerFlap .............................................................. 2
13.2.1
............ Doors. Description ................................................................... 2
13.2.2
............ Front Door Trim Pad Veneer Panel. Renew ......................... 76.47.11 ............. 2
13.2.2.
...........
13.2.3 ............ Rear Door Upper Trim Pad. Remove For Access and Refit ............ 76.34.05/90 .......... 3
13.2.5.
........... Rear Door Window Lift Switch Veneer Panel. Renew ................ 76.47.34 ............. 3
13.2.6.
........... Rear Door Lower Trim Pad, Remove for Access and Refit ............. 76.34.06/90 .......... 4
13.2.7
............ Rear Door Lower Trim Pad, Renew ............................... 76.34.06 ............. 4
13.2.8.
........... Rear Door Armrest. Renew ...................................... 76.34.23 ............. 5
13.2.9 ............ Rear Door Pocket, Renew ....................................... 76.34.28 ............. 5
13.2.10 .......... Front Door Upper Trim Pad, Renew ..................................................... 6
13.2.11 ........... Front Door Lower Trim Pad, Renew ..................................................... 6
13.2.12 .......... DoorLock Barrel, Renew .............................................................. 6
13.2.13 Front
or Rear Door Lock Striker, Renew .................................................. 6
13.2.14
.......... Front or Rear Door Outer Handle Operating Rod, Renew ................................... 6
13.2.15 .......... FrontArmrest, Renew ................................................................. 7
13.2.16 .......... Front or Rear Armrest Support. Renew ................................................... 7
13.2.17 .......... Front Door Pocket. Renew ............................................................. 7
........................................................... 8
Rear
Door Trim
Pad Veneer Panel. Renew .......................... 76.47.12 ............. 2
13.2.4
............ Rear Door Upper Trim Pad, Renew ............................... 76.34.05 ............. 3
..........
13.2.18 .......... Fuel Filler Flap, Description
13.2.19
.......... Filler Flap and Hinge, Renew .......................................................... 8
13.2.20
.......... Filler Cap Retention Magnet. Renew .................................................... 8
.......... Filler Flap Latching Assembly, Renew ................................................... 8
13.2.21
13.3
............. Passenger Compartment ............................................................... 9
13.3.1
............ Console Assembly, Remove for Access and Refit .................... 76.25.01/90 .......... 9
13.3.2
............ Console Assembly, Renew (Daimler/ VDP) ........................ 76.25.07/50 ......... 10
13.3.3
............ Console Assembly, Remove for Access and Refit (Daimler/ VDP) ...... 76.25.01/91 ......... 12
13.3.4
............ Console Assembly, Renew ....................................... 76.25.01 ............ 13
13.3.5
............ Console Rear Extension Finisher, Renew ........................... 76.25.04 14
Selector Trim Finisher, Renew (3.2 Liter)
........................... 76.25.07 ............ 14
Modeswitch Finisher, Renew .................................... 76.25.09 ............ 15
13.3.10
.......... Radio Console, Renew .......................................... 76.25.15 ............ 16
Console Glove Box, Renew
...................................... 76.25.16 ............ 17
Console Glove Box Lid, Renew ................................... 76.25.18 ............ 18
.......... Console Glove Box Lid Hinge, Renew ............................. 76.25.20 ............ 19
13.3.14
.......... Cupholder Trim Panel, Renew .................................... 76.25.21 ............ 19
13.3.15 .......... Cupholder, Renew ............................................. 76.25.22 ............ 20
.......... Cupholder Latch, Renew ........................................ 76.25.23 ............ 20
Fascia Board, Renew ........................................... 76.46.01 ............ 21
13.3.6
............ Console
Rear Extension. Renew .................................. 76.25.05 ............ 14
13.3.7
............
13.3.8. ........... Selector Trim Finisher, Renew (4.0 Liter, 4.0 Liter SC and 6.0 Liter) ..... 76.25.07 ............ 15
13.3.9
............
............
13.3.11 ...........
13.3.12
13.3.13 ..........
13.3.16
13.3.17
..........
13.3.18 .......... Fascia Board. Remove for Access and Refit ......................... 76.46.01/90 ......... 24
X300 VSM i Issue 1 August 1994

SECTION CONTENTS
Sub-Section Title SRO Page
13.3.19 .......... Underscuttle Pad. Drivers Side. Remove for Access and Refit .......... 76.46.1 1/90 ......... 26
13.3.20
.......... Underscuttle Pad. Passenger Side. Remove for Access and Refit ....... 76.46.15/90 ......... 26
13.3.21
.......... Fascia Closing Panel - Passenger Side. Renew ...................... 76.46.27 ............ 27
13.3.22
.......... Fascia Closing Panel -Drivers Side. Renew ......................... 76.46.28 ............ 27
13.3.23
.......... Fascia Center Veneer Panel. Renew ............................... 76.47.06 ............ 28
13.3.24
.......... Console Finisher Veneer Panel. Renew ............................ 76.47.26 ............ 29
13.3.25 .......... Console Ashtray Lid Veneer Panel. Renew ......................... 76.47.27 ............ 30
13.3.26 .......... Console Ashtray Surround Veneer Panel. Renew .................... 76.47.28 ............ 30
13.3.27
.......... Console Rear Extension Veneer Panel. Renew ...................... 76.47.30 ............ 30
13.3.28 .......... Console Ashtray, Renew ......................................... 76.67.18 ............ 31
13.3.29
.......... Steering Column Upper cowl. Renew ............................. 76.46.02 ............ 32
13.3.30
.......... Steering Column Lower cowl. Renew ............................. 76.46.03 ............ 32
13.3.3
1 .......... Steering Column Switchgear Mounting Bracket. Renew .............. 76.46.33 ............ 33
13.3.32
.......... 'A' Post Lower Trim Pad. Renew .................................. 76.13.30 ............ 35
13.3.33
.......... Rear Quarter Upper Trim Pad. Renew .................................................. 35
13.3.34
.......... 'B' Post Upper Trim Pad. Renew ....................................................... 35
13.3.35 .......... 'B' Post Lower Trim Pad. Renew ....................................................... 35
13.3.36 .......... Handbrake Lever Trim. Renew ........................................................ 35
13.3.37
.......... Combined Grab Handle and Coat Hanger Hook. Renew .................................. 35
13.3.38
.......... Sun Visor Assembly RH or LH. Renew .................................................. 36
13.3.39
.......... Roof Lining (Headlining). Description .................................................. 37
13.3.40
.......... Roof Lining. Renew ................................................................. 37
13.4 ............. Trunk ........................................................................\
..... 38
13.4.1
............ Trunk. Description .................................................................. 38
13.4.2.
........... Trunk Side Liner - Left Hand. Renew .............................. 76.19.22 ............ 39
13.4.3
............ Trunk Side Liner - Right Hand. Renew ............................. 76.19.23 ............ 39
13.4.4
............ Trunk Floor Carpet. Renew ...................................... 76.19.30 ............ 39
13.4.5.
........... Trunk Front Liner, Renew ........................................ 76.19.3 1 ............ 39
13.4.6.
........... Trunk Seal Retainer, Renew ...................................... 76.19.44 ............ 40
13.4.7.
........... Trunk Lid Striker, Adjust .............................................................. 40
13.4.8
............ Trunk Lid Liner, Renew ............................................................... 40
13.4.9
............ Trunk Seal Retainer, Renew ........................................................... 40
13.4.10
.......... Trunk Lid Lock Striker, Renew ......................................................... 40
13.4.11
........... Trunk Lid Lock Barrel. Renew ......................................................... 40
13.4.12
.......... TrunkLidLockMechanism. Renew .................................................... 41
13.3.13
.......... Trunk Lid Gas Strut. Adjust. Renew .................................................... 41
13.4.14
.......... Trunk LidHinge. Renew .............................................................. 41
13.4.15 .......... Trunk Rear Liner, Renew ............................................................. 41
13.5
............. Hood ........................................................................\
..... 42
13.5.1
............ Hood Description ................................................................... 42
13.5.2
............ Plenum Chamber Finisher, Renew ................................ 76.10.01 ............ 42
13.5.3 ............ Hinge. Renew ...................................................................... 42
13.5.4
............ Gasstrut. Renew .................................................................... 43
13.5.5
............ HoodLockRHorLH. Renew ......................................................... 43
issue 1 August 1994 X300 VSM

Body Components & Trim .
SECTION CONTENTS
Sub-Section Title SRO Page
13.5.6 ............ Hood lock Control Cable RH or LH, Renew ............................................. 43
13.5.7.
........... Hood Striker Assembly, Renew ........................................................ 43
Hood lock Release Handle. Renew
.................................................... 43
13.5.8 ............
13.6 ............. Glazing (Fixed) ..................................................................... 44
13.6.1
............ Glazing (Fixed). Description .......................................................... 44
13.6.2.
........... Interior Mirror, Renew ............................................................... 44
13.6.3.
........... Sun Visor Mirror Assembly, Renew ..................................................... 44
13.6.4.
........... Exterior Mirror, Renew ............................................................... 44
13.6.5
............ Exterior Mirror Glass, Renew .......................................................... 44
13.7
............. Carpets ........................................................................\
.... 45
13.7.1
............ Carpets, Description ................................................................. 45
13.7.2.
........... Removal of Stains - General Information ................................................ 45
13.7.3.
........... Powder Cleaning - Removal of Small Spillage Stains ...................................... 45
13.7.4
............ Spot Cleaning- LocalizedStains ...................................................... 46
13.7.6
............ RepairofDamagedCarpet ........................................................... 47
e
13.7.5. ........... Carpet Cleaning and Stain Removal Materials ........................................... 47
13.8
............. Seating and Seat Belts ................................................................ 48
13.8.1
............ Seating, Description ................................................................. 48
Front Manual Seat, Renew
............................................................ 48
13.8.3.
........... Front Seat (Power Operated), Renew ................................................... 48
13.8.2
............
13.8.4 ............ Front
Seat Head Restraint (Power Operated), Renew ...................................... 49
13.8.5.
........... Front Seat Head Restraint (Power Operated), Renew ...................................... 49
13.8.6
............ RearSeat Cushion. Renew ............................................................ 49
13.8.7 ............ RearSeatSquab. Renew ............................................................. 49
73.8.8 ............ Seat Belts, Description ............................................................... 50
13.8.9 ............ Emergency Locking Retractor/ Automatic Locking Retractor Seat Belts ...................... 50
13.8.10
.......... Tear loop Seat Belts, Description ...................................................... 51
13.8.1 I ........... Front Seat Belt Buckle Unit, Renew .................................................... 52
13.8.12
.......... Front Seat Belt, Renew ............................................................... 52
13.8.13
.......... Rear Inertia Seat Belt, Renew ......................................................... 52
13.8.14
.......... Rear, Center, Static Seat Belt, Renew ................................................... 53
iii Issue 1 August 1994

1. SERVICE TOOLS & EQUIPMENT
Illustration Jaguar Number Description Notes
not illustrated JD 188 Underscuttle pad securing SRO 76.46.1 1/90 and
not illustrated JD
202 Fascia center vent removal SRO 76.46.06
clip removal tool SRO 76.46.15190
tool
11. TORO U€ TIGHTEN1 NG SPEC1 FlCA TlONS
Fixing Tightening Torque (Nm) 1
Fascia I I
Instrument pack to support panel I 1.8 I
Fascia to support bracket
Fascia to console
3
Tunnel bracket to body
22 - 28
22
- 28
Bolster to tunnel bracket 1.5
Instrument pack to fascia
3.0
Strut to fascia 2.0
Fascia support strut to body 7 - 10
CPU bracket to fascia 5
-7
Fascia demister bracket to fascia
1.5
1 .o
1 .o
5-7
5
-7
Fascia
and air con. location to body
Air dist. box duct to air dist. box
Airbag carrier mounting bracket to fascia
Instrument pack support bracket to fascia
Airbag bracket to fascia
2.0
Air dist. box to fascia 2.0
Inst. pack support bracket to fascia 5-7
22 - 28 Fascia assembly to body
Airbag door brackets to fascia 5-7
4.0
4.0
Airbag door bracket to fascia and strut
Airbag door bracket to door frame assembly
Hood
Hood lock to body
Hood buffer assembly 7
-10
Gas strut - ball pin to weld nut
7 - 10
7
- 10
Hood lever 5
-7
Clamp
- hood adjust cable 6-8
Interior
Sun Visor fixings 1.8
Sunblind to parcel shelf
Sunblind bezel assembly
1 .o
Coat hook 3.0
Tighten to prevailing torque

Body Components & Trim -
Fixing
Seat belts
Front tear loop belt buckle to bracket fixing
Front belt buckle to bracket fixing
Tightening Torque (Nm)
30 - 40
30
- 40
Front belt reel bracket to body fixing
Front belt anchor fixing 30 - 40
30 - 40
7
-10
23
- 27
30
- 40
30 - 40
30
- 40
30 - 40
30
- 40
Front belt upper guide fixing
[Height adjuster to 'B' post screws
Height adjuster to seat belt anchor retaining
nut
Rear inertia belt anchor fixing
Rear inertia belt bracket to body fixing
Rear inertia belt reel securing bracket to body fixing
Rear inertia
/ static belt buckle bracket to body fixing ~
Rear
static belt / inertia buckle bracket to body fixing
: Sunroof ~
Sunroof frame
to roof
30 - 40
4
-5
111. SERVICE MATERIALS
Sunroof to frame 4-5
'Trunk
Compact disc autochanger bracket to body
I Battery clamp to tray
I Warning triangle lower bracket to trunk lid inner panel
9- 11
7
-10
1.5
X300 VSM V Issue 1 August 1994
I trunk lock barrel to lid
j Trunk latch actuator to bracket
Trunk latch actuator mounting to
lid
j Electrical carrier box to body
Load floor support block to body
Trunk seal retainer to body
trunk latch to lid and striker to body
4-5
7
-10
7
-10
7
-10
5
-7
9- 11
9- 11
Description Uses
'Fibrefresh' Carpet Shampoo
'1001' Foam Shampoo
'Novatreat' Cleaning
of water
-based stains from
carpets
Cleaning of water
-based stains from
carpets
Cleaning of water
-based stains from
carpets
Notes
'Genklene' (Trichloroethane)
'Spot Remover' Cleaning
of grease or oil based
stains from carpets
Cleaning of grease or oil based
stains from
caroets